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CPS DPA03-800V User manual

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Installation and Operation Manual
for CPS DPA03-800V/US AC Combiner
CHINT POWER SYSTEMS AMERICA CO., LTD.
Rev 3.2 Jan 12, 2023 Doc. No.: 9.0020.0589C0
Table of Contents
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Table of Contents
0 Preface ............................................................................................ 4
1 Safety .............................................................................................. 5
Symbols and meanings in this document ................................................... 5
Markings and meanings on the device ....................................................... 5
Safety precautions of operating the Combiner ........................................... 6
2 General Introduction...................................................................... 7
Overview of grid-tied PV system ................................................................ 7
Appearance and dimensions ...................................................................... 7
Features of AC Combiner ........................................................................... 8
Nameplate .................................................................................................. 9
2.4.1 Model No. .......................................................................................... 9
2.4.2 Serial No. ......................................................................................... 10
Circuit structure design ............................................................................. 11
Storage requirements ............................................................................... 12
3 Mechanical Installation ............................................................... 13
Unpacking for inspection .......................................................................... 13
Installation requirements .......................................................................... 14
3.2.1 Environment requirements ............................................................... 14
3.2.2 Installation requirements .................................................................. 14
Installation procedures ............................................................................. 14
3.3.1 Installation with CPS Cluster Mount ................................................. 14
3.3.2 Installation with CPS In-line Cluster Mount ...................................... 19
3.3.3 Installation on other structures ......................................................... 22
Open and close the door .......................................................................... 23
3.4.1 Open the door .................................................................................. 24
3.4.2 Close the door ................................................................................. 24
4 Electrical Connection .................................................................. 26
Internal wiring terminals and cable specification ...................................... 26
Recommended tools and torque values ................................................... 27
Wiring ....................................................................................................... 28
4.3.1 Cable connection ............................................................................. 28
4.3.2 Create conduit entry holes ............................................................... 29
5 Operation and Maintenance ........................................................ 30
Start up and shut down ............................................................................ 30
Table of Contents
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5.1.1 Start up ............................................................................................ 30
5.1.2 Shut down ........................................................................................ 30
Maintenance ............................................................................................. 31
5.2.1 Regular inspection ........................................................................... 31
5.2.2 Fuse replacement ............................................................................ 31
6 Technical Data .............................................................................. 32
7 Limited Warranty .......................................................................... 33
8 Contact Information ..................................................................... 34
9 Appendix ....................................................................................... 35
Appendix A: Figure list .............................................................................. 35
Appendix B: Table list ............................................................................... 35
Preface
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0 Preface
Thank you for choosing CPS DPA03-800V/US Series AC Combiner (hereinafter
referred to as "Combiner") developed by CHINT POWER SYSTEMS AMERICA CO.,
LTD (hereinafter referred to as "CPS").
This Combiner is one highly reliable device, which is widely applicable in AC
combining of various PV systems.
IMPORTANT!
Please read this manual carefully and make sure that you have
understood all the contents thoroughly before you start any operation.
Main Contents
Safety precautions, device overview, installation, operation and maintenance,
technical data as well as quality assurance are mainly introduced in this manual.
Target Reader
This manual is applicable to the work staff of wiring, installation, operation and
maintenance of the Combiner.
Manual Management
Please store this manual together with related documents of other device
components and keep it readily accessible at all times for quick reference and easy
use.
Copyrights
CPS reserves all rights in this manual. Any reproduction, disclosure or copy in whole
or in part is forbidden without prior written authorization. CPS doesn’t accept any
responsibilities whatsoever for potential errors or possible lack of information in this
document.
Version
This manual is subject to technical change or contents modification without prior
notice. The version applicable to the purchased device shall prevail. Users can get
the latest manual from our sales channel or our official website:
www.chintpowersystems.com/
Safety
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1 Safety
Please read this user manual carefully before the installation and operation of this
Combiner. CPS reserves the right to refuse warranty claims for equipment damages
if users fail to install the equipment according to the instructions in this manual.
Symbols and meanings in this document
Markings and meanings on the device
Symbol
Meanings
HIGH VOLTAGE!
Danger to life due to high voltage!
All work on the device must only be performed by qualified personal
as described in this document.
HOT!
The equipment is designed according to international safety
standards, but surfaces can become hot during operation. DO NOT
touch the peripheral surfaces during or shortly after operation.
EARTH GROUND!
This symbol marks the location of grounding terminal, which must be
securely connected to the earth through the protective earth (PE)
cable to ensure operational safety.
Symbol
Meanings
DANGER!
DANGER indicates a hazardous situation with high level of risk which, if
not avoided, will result in death or serious injury.
WARNING!
WARNING indicates a hazardous situation with medium level of risk
which, if not avoided, could result in death or serious injury.
CAUTION!
CAUTION indicates a hazardous situation with low level of risk which, if
not avoided, could result in minor or moderate injury.
NOTICE!
NOTICE indicates a hazardous situation which, if not avoided, could
result in equipment working abnormally or property loss.
IMPORTANT!
IMPORTANT indicates important supplementary information or provides
skills or tips that can be used to help you solve a problem or save you
time.
Safety
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RoHS SYMBOL
In accordance with 2011/65/EU regulations, the inverter imposes
restrictions on the use of specific hazardous substances in electrical
and electronic equipment.
TUV Certification
This inverter has passed testing and received certification from the
organization TUV Rheinland.
Safety precautions of operating the Combiner
Symbol
General Introduction
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2 General Introduction
Overview of grid-tied PV system
The grid-tied PV system is generally made up of PV modules, PV string inverters, AC
Combiners, and other electrical balance of system components. Solar irradiation is
converted to DC electricity by PV modules, then distributed to each PV string inverter
as the first level of current combination. Then, PV string inverter outputs are
connected to the AC Combiner for second level of current combination. The AC power
then has the same frequency and phase with the grid. This power can supply onsite
loads or be injected into the local grid.
This AC Combiner shall be used in combination with CPS SCH275KTL-DO/US-800
series string PV inverters.
For the position and function of the AC Combiner in the grid-tied PV system, refer to
Figure 2-1.
Figure 2-1 Grid-tied PV system
Appearance and dimensions
General Introduction
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Figure 2-2 Product Dimensions
Figure 2-3 Product Appearance
Item No.
Component Name
1
Hasp locks (refer to Open the door)
2
Operation handle
3
Hooks
Table 2-1 Component Name
Features of AC Combiner
- High performance, reliable design.
- High-voltage switch equipped with TYPE3R outdoor operation handle,
which is designed specifically for a PV system.
- Door cannot be opened once the machine is powered ON.
- A transparent protection board is installed in front of the live components
to avoid access to live conductors.
- Powerful protection performance.
- Equipped with high-current load-break switch and high-voltage AC fuse.
- Available space to place a padlock on the disconnect switch handle for
lockout/tagout purposes.
- Convenient installation and maintenance.
- Installs easily on mounting bracket.
- No locking screws are required.
General Introduction
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Nameplate
The device nameplate contains important information of the device, including model
number, serial number and detailed parameters, etc.
You can find the nameplate of Combiner on the right side of its enclosure, as shown
in Figure 2-4.
Figure 2-4 Nameplate
2.4.1 Model No.
You can find out the model number of the Combiner on the nameplate, as shown in
figure 2-4. Each character included in the model has its special meanings, as shown
in Figure 2-5.
Figure 2-5 Naming convention of the model
General Introduction
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2.4.2 Serial No.
The serial number can be found out at the bottom left corner in the inner side of the
door, as shown in Figure 2-6 (for reference).
Figure 2-6 Serial No.
The serial number is a list of 11 numbers and each number has its special meanings,
the bar code is made up of 128 codes, as shown below (just for reference).
Figure 2-7 Naming convention of the serial no.
IMPORTANT!
If there is any problem or malfunction of the device during operation
in the future, you can contact our after-sales service center and
provide the device serial number.
Please keep the nameplate intact, as our service personnel will
request the product information to determine the date of production
and other necessary information to help service the unit.
General Introduction
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Circuit structure design
The main electrical schematic diagram of the AC Combiner is shown in Figure 2-8.
The AC power from the PV inverters is fed to the AC fuses of the Combiner and then
output through the disconnect switch. The disconnect switch can meet the input
requirements of the 800VAC power.
Note: PE=Protective earthing
Figure 2-8 Basic Electrical Schematic Diagram of the AC Combiner
General Introduction
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Storage requirements
• Close the door tightly, to minimize the risk of accidental opening.
• Storage space shall be clean and dried and be free from dust or
moisture.
• The temperature of the storage space shall be kept between -40℃
and +70℃ as shown below.
• The relative humidity of the storage space shall be kept between 5%
and 95% as shown below.
Figure 2-9 Temperature and Relative Humidity of the Storage Space
Mechanical Installation
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3 Mechanical Installation
Unpacking for inspection
Before installing, check the product for any obvious damage and confirm that each of
the items in the delivery list shown below are present. Contact your supplier
immediately if any problem is found. The delivery list of the Combiner is as below:
No.
Images
Accessories
QTY (pcs)
1
AC Combiner
1
2
M12*50 screw, Bolt grade 8.8
Min. breaking torque (80 N.m)
42
3
M12 nut
46
4
M12 flat washer
92
5
M12 spring washer
46
6
M4*12 comb. screw, bolt grade 8.8,
Min. breaking torque (2.6 N.m)
6
7
Fixed bracket
2
8
Mounting bracket
2
9
M12*40 screw, bolt grade 8.8,
Min. breaking torque (80 N.m)
4
10
One manual and one warranty card
2
Table 3-1 Delivery List
Mechanical Installation
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Installation requirements
3.2.1 Environment requirements
• Inflammable and explosive materials inside and around the inverter are
strictly prohibited.
• Good ventilation around the equipment shall be kept.
• The temperature shall be kept within -30°C ~ +60°C. For environments
with temperatures that may exceed 55°C, please choose installation
sites with shelters or build sunshades as needed.
• It is not recommended to expose the device to heavy rain. Water that
is sufficiently deep may enter the device through the cable entry holes
in the bottom of the Combiner.
3.2.2 Installation requirements
• Make sure the device is not electrically connected and energized
before installing.
• Never install, use or maintain the device in lightning, rain, snow, wind
and other severe weather.
• Do not wear conductive objects such as watches, bracelets, rings, and
necklaces when installing, operating, or maintaining the device.
• After installing devices, remove empty packing materials such as
cartons, foams, plastics, and cable ties.
• The paint scratches on the cabinet body caused in the process of
transportation and installation must be repaired in time. It is strictly
prohibited to expose the scratched parts to the outdoor environment
for long periods of time.
Installation procedures
WARNING!
All the installation and wiring connections should be performed only by
qualified technical personnel.
CAUTION!
Heavy device, handle it carefully to prevent it from tipping or falling.
3.3.1 Installation with CPS Cluster Mount
IMPORTANT!
All the accessories needed to install the combiner are provided with the
combiner (but may ship separately).
Mechanical Installation
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Install the AC Combiner mounting bracket pieces as shown below:
1. Take out the mounting brackets from the AC Combiner accessory bag. Fix
the two mounting brackets (1) with four M12X40 bolt combinations onto the
two vertical beams (2), tighten all these bolts with four M12 nuts, torque
value: 49±5 N.m (434±43 in-lbs).
Figure 3-1 Fix Mounting Brackets onto the Vertical Beams
2. Take out the fixed brackets from the AC Combiner accessory kit. Position
one fixed bracket (2) onto the fixed hole on the outer edge of the mounting
bracket (3) and fasten it with one M4*12 securing screw (1) via screwdriver
as shown, torque value: 1.5N.m (14 in-lbs).
Figure 3-2 Position of Fixed Bracket
Mechanical Installation
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3. Hoist the bottom of the Combiner till all its hooks (4) are aligned with the
mounting bracket (3) and hang them onto the mounting brackets of the rack.
4. This can be achieved by hoisting the Combiner with a hydraulic vehicle or
forklift in accordance with the following method:
(1) Find the center of gravity of the Combiner as shown below.
Figure 3-3 Center of Gravity of the Combiner
(2) Keep the center of gravity in the central position of the forklift to avoid
the Combiner tilting. Strap combiner as appropriate to ensure secure
lift and installation.
Figure 3-4 Hoist the Combiner with a Forklift
NOTICE
Never fasten the fixed bracket to drain holes in the center of the U-type
groove. Otherwise, it cannot be fastened onto the hooks of the Combiner
in step 5.
Mechanical Installation
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WARNING!
All the hoisting operations should be performed only by qualified
technical personnel to guarantee the Combiner will not tilt or fall.
Operate the hydraulic vehicle or forklift on level ground to prevent the
vehicle and the Combiner tilting.
The center of gravity of the Combiner shall be kept in the central
position of the hoisting fork.
During all the hoisting operations, the hoisting fork shall be kept
horizontal to avoid the Combiner tilting or falling.
(3) Slide the side plate of Combiner along the mounting bracket, until it
stays closely with the fixed bracket.
Figure 3-5 Slide the Combiner
(4) Fasten the fixed bracket onto the hooks of the Combiner by screwing
another two M4*12 securing screws into the holes of the fixed bracket,
torque value 1.5N.m (14 in-lbs). Fasten the fixed bracket onto the
hooks of the Combiner by screwing another two M4*12 securing
screws into the holes of the fixed bracket.
NOTICE!
The weight of the device is about 120 kg. For safety purpose, please
hoist it with forklift or hydraulic vehicle as far as possible.
The handrails on both sides of the device are designed for manual
lifting when lifting equipment is not available.
Mechanical Installation
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Figure 3-6 Fasten the Fixed Bracket
5. Finally, fasten another fixed bracket onto the other side of the mounting
bracket with the remaining three M4*12 securing screws to avoid the
accidental movement of the Combiner (refer to the step 2 and step 5).
IMPORTANT!
For the assembly instructions and assembly procedures of the integrated
bracket, please download the specific manual for the CPS Cluster Mount
from our official website.
Mechanical Installation
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3.3.2 Installation with CPS In-line Cluster Mount
IMPORTANT!
All the accessories needed to install the combiner are provided with the
combiner (but may ship separately).
Install the AC Combiner on the Cluster as shown below:
1. Take out mounting brackets from the AC combiner accessory bag. Fix the
two mounting brackets (1) with four M12X40 bolt combinations onto one
group of equipment suspension beams (2). Tighten all these bolts with four
M12 nuts, torque value: 52.0 N.m, 458.0 in-lbs.
Figure 3-7 Fix the Two Mounting Brackets onto the Two Vertical Beams
2. Take out fixed brackets from the AC combiner accessory bag. Position one
fixed bracket (2) onto one side of the mounting bracket (3) and fasten it with
one M4*12 securing screw (1) via screwdriver as shown, torque value:
1.6N.m, 14.1 in-lbs.
Figure 3-8 Position one fixed bracket
Mechanical Installation
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3. Hoist the bottom of the Combiner until all its hooks (1) are aligned with the
mounting bracket (2) and hang them onto the mounting brackets of the rack.
It can be achieved by hoisting the Combiner with a hydraulic vehicle or
forklift in accordance with the following method:
(1) Find the center of gravity of the Combiner as shown below.
Figure 3-9 Center of Gravity of the Combiner
(2) Keep the center of gravity in the central position of the hoisting fork to
avoid the Combiner tilting.
Figure 3-10 Hoist the Combiner with Hoisting Forklift
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